HYDRAULIC RAIL SAW - Stanley Hydraulic Tools
Contents
1. 22439 Railsaw Blade 16 inch Norton Norzone lll Fastcout ss 29745 Railsaw Blade 14 inch Norton Norzone lll Fastcout 3388488338 3333933333 30974 Seal Kit Includes 66399 JIHOSTROJ Seal Kit 31845 Motor Seal Kit Assy Serial No 3585 included in 31845 66399 Universal Bellcrank EE REE m 34733 Motor Upgrade Kit 14 inch Model After Serial No 2598 66191 Includes 65625 Disconnect Pivot Bolt 65626 Pivot Tube 65627 Indicator Rod 66133 Motor Assy Motor Upgrade Kit 16 inch Model After Serial No 2598 66192 Includes 65625 Disconnect Pivot Bolt 65626 Pivot Tube 65627 Indicator Rod 66134 Motor Assy 16 RS25 User Manual STANLEY HONI VL L99 N d HONI 9L Y 99 N d ay RS25 PARTS ILLUSTRATION 90299 N d ASSY LN313Q 621 amp IN3 LI 82199 4 7 ASSV dAW19 1174 Lel INL 776 v 2 33 B SE ES 7 pe uonejuaug J9usew v 7 10130 ES Mu SS LLOZ YEN L 8 PL MVS TIVA 5254 RS25 User Manual 4 17 RS25 PARTS LIST PART ITEM NO QTY DESCRIPTION s mw BELLCRANK 000 26 T seFERTOrTEM 131 0 we2. PROTECT YOUR EYES 12 WEAR SAFETY GOGGLES 1 DO NOT USE DAMAGED WHEELS 2 USE FULL TROTTLE ONLY WHILE CUTTING 3 USE ONLY WHEELS MARKED HIGH SPEED REINFORCED THAT MEET REQUIREMENTS OF ANSI B7 1 B7 5 WHEELS SHOULD BE NO LARGER THAN 16 DIA X 5 32 THICK WITH A 1 ARBOR HOLE amp RATED FOR 4700 RPM MINIMUM SPEED 4 INSPECT WHEEL GUARD amp COLLARS FOR DAMAGE AFTER ANY WHEEL BREAKAGE ON THE MACHINE 5 MAXIMUM SPINDLE SPEED IS 4700 RPM 6 READ OPERATION MANUAL 17641 Abrasive Cut Off Safety Label 16 inch models only DANGER DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT ABUSE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE MAKE SURE HYDRAULIC HOSES ARE PROPERLY CON NECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CON NECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNECTIONS MAY CAUSE REVERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA WEAR HEARING EYE FOOT HAND AND HEAD PRO TECTION TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE ALL TOOL REPAIR MAINTENANCE AND SERVICE MUST ONLY BE PERFORMED BY AUTHORIZED AND PROPERLY TRAINED
3. eui dee o pepuojur 9Je 5001 epueuuuloo2aJ esau uldi eyjnuiu Jed SJEN udp aynuiu sed suoyef uo peseq suj6us SOU SNOWeA JO sJejeuleip esou WNWIUIW pepueuuulooaJ SMOUS 14011 v O yeyo SUL SOH UNIID lineipAH 03 JOO RS25 User Manual 49 HTMA EHTMA REQUIREMENTS HTMA EHTMA REQUIREMENTS HTMA TOOL TYPE HYDRAULIC SYSTEM REQUIREMENTS TYPE II TYPERR TYPE II Flow Range 4 6 gpm 7 9 gpm 9 10 5 gpm 11 13 gpm 15 23 lpm 26 34 lpm 34 40 lpm 42 49 lpm Nominal Operating Pressure 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 103 bar 103 bar 103 bar 103 bar System relief valve setting 2100 2250 psi 2100 2250 psi 2200 2300 psi 2100 2250 psi at the power supply outlet 145 155 bar 145 155 bar 152 159 bar 145 155 bar Maximum back pressure 250 psi 250 psi 250 psi 250 psi at tool end of the return hose 17 bar 17 bar 17 bar 17 bar Measured at a max fluid viscosity of 400 ssu 400 ssu 400 ssu 400 ssu at min operating temperature 82 centistokes 82 centistokes 82 centistokes 82 centistokes Temperature Sufficient heat rejection 140 F 140 F 140 F 140 F capacity to limit max fluid temperature to 60 C 60 C 60 C 60 C at max expected ambient temperature Min cooling capacity at a temperature 3 hp 5 hp 6 hp 7 hp difference of between ambient and fluid 2 24 kW 3 7
4. STANLEY RS25 HYDRAULIG RAIL SAW SAFETY OPERATION AND MAINTENANCE USER MANUAL O 2011 Stanley Black amp Decker Inc New Britain CT 06053 U S A 31846 12 2013 Ver 10 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY UBEREINSTIMMUNGS ERKLARUNG C 6 DECLARATION DE CONFORMITE CEE DECLARACION DE CONFORMIDAD Hydraulic Tools DICHIARAZIONE DI CONFORMITA 1 the undersigned Ich der Unterzeichnende Weisbeck Andy Je soussign El abajo firmante lo sottoscritto Surname and First names Familiennname und Vornamen Nom et pr nom Nombre y apellido Cognome e nome hereby declare that the equipment specified hereunder best tige hiermit da erklaren Produkt genannten Werk oder Ger t d clare que l quipement vis ci dessous Por la presente declaro que el equipo se especifica a continuaci n Dichiaro che le apparecchiature specificate di seguito 1 Category Rail Saw Hydraulic Kategorie Cat gorie Categoria Categoria 2 Make Marke Marque Marca Marca Stanley 3 RS25103 4 Serial number of equipment Seriennummer des Gerats Num ro de s rie de l quipement All Numero de serie del equipo Matricola dell attrezzatura Has been manufactured in conformity with Wurde hergestellt in Ubereinstimmung mit Est fabriqu conform ment Ha sido fabricado de acuerdo con E stata costruita in conformita con Directive Standards No Approved body Ric
5. PERSONNEL IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE SAFETY TAG P N 15875 Shown smaller then actual size RS25 User Manual 7 HOSE TYPES The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hy draulic system There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools They are Certified non conductive constructed of thermoplastic or synthetic rubber inner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover Hose labeled certified non conductive is the only hose authorized for use near electrical conductors Wire braided conductive constructed of synthetic rubber inner tube single or double wire braid reinforce ment and weather resistant synthetic rubber cover This hose is conductive and must never be used near electrical conductors Fabric braided not certified or labeled non conductive constructed of thermoplastic or synthetic rubber in ner tube synthetic fiber braid reinforcement and weather resistant thermoplastic or synthetic rubber cover This hose is not certified non conductive and must never be used near electrical
6. Stanley Hydraulic Tools Supply hoses must have a mini mum working pressure rating of 2500 psi 172 bar 14 RS25 User Manual Do not exceed the rated flow see Specifications in this manual for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended TROUBLESHOOTING If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation of the grinder always check that the hydraulic power source is supplying the correct hydraulic flow and pressure to the grinder as listed in the table Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C SYMPTOM POSSIBLE CAUSE SOLUTION Saw does not run Hydraulic power source not Check power source for proper flow functioning correctly and pressure 7 10 gpm 26 34 Ipm 2000 psi 140 bar Coupler or hoses blocked Remove obstruction Mechanical failure Have tool serviced by authorized dealer Saw runs backwards Pressure and return lines incorrectly Correct hose connections Motor connected shaft rotates counter clockwi
7. cm Overall Height w wheel guard rotated to any position 13 inches 33 cm Weight less wheel Tel M 55 Ibs 24 4 kg TO MEV GET ROS Meum TC 56 Ibs 25 kg RPM LE 11101 11080 EEE EE EN E EE ENE 4500 16 MeN MO b 03 3 4000 Maximum Fluid Temperature us nico 140 F 60 C 5102 5 eee o HH 75 165 Ib yard 37 82 kg M Sound and Vibration Declaration Test conducted on RS25103 operated at standard 10 gpm input 7 Measured A vveighted sound power level Lvva ref 1pW in decibels 108 dBA Uncertainty Kvva in decibels 3 dBA Measured A weighted sound pressure level Lpa ref 20 uPa at operator s position in decibels 97 dBA Uncertainty Kpa in decibels 3 dBA upper boundary of the range of values which is likely to occur in measurements Declared vibration emission value in accordance with EN 12096 Values determined according to noise test code given in ISO 15744 using the basic standard ISO 3744 NOTE The sum of a measured noise emission value and its associated uncertainty represents an Measured vibration emission value a Uncertainty K Values determined according to ISO 8662 1 ISO 5349 1 2 ACCESSORIES Railsaw Blade 16 inch Norton AT 36
8. 3 kW 5 22 kW 4 47 kW temps 40 F 40 F 40 F 40 F NOTE 22 C 22 C 22 C 22 C Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause operator discomfort at the tool Filter m 25 microns 25 microns 25 microns 25 microns Min full flovv filtration 30 gpm 30 gpm 30 gpm 30 gpm 5 dm 00400 d m dirt holding capacity Hydraulic fluid Petroleum based 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu premium grade anti vvear non conductive 20 82 centistokes Viscosity at min and max operating temps NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the requirements over a wide range of operating temperatures SSU Saybolt Seconds Universal EHTMA CLASSIFICATION HYDRAULIC SYSTEM mE A A A A Flow Range 3 5 4 3 gpm 4 1 5 8 gpm 7 1 8 7 gpm 9 5 11 6 gpm 11 8 14 5 gpm 13 5 16 5 Ipm 18 22 lpm 27 33 Ipm 36 44 Ipm 45 55 Ipm Nominal Operating Pressure 1870 psi 1500 psi 1500 psi 1500 psi 1500 psi at the power supply outlet 129 bar 103 bar 103 bar 103 bar 103 bar System relief valve setting 2495 psi 2000 psi 2000 psi 2000 psi 2000 psi at the power supply outlet 172 bar 138 bar 138 bar 138 bar 138 bar NOTE T
9. 3810 SE Naef Road Milwaukie Oregon 97267 5698 USA 503 659 5660 Fax 503 652 1780 www stanleyhydraulic com
10. ATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC Hu SEE OTHER SIDE n Pn SEE OTHER SIDE OVL SIHL AAOWSY LON OG 0 lt x 2 I He LU gt O LU nz Shown smaller than actual size 8 RS25 User Manual STANLEY 0 lt o lt P Q LLI c LLI 0 O IE SUONDSUUON 6214 0100 RETURN HYDRAULIC CIRCUIT PRESSURE lt lt lt 4 MOT4 gt gt gt JYNSSIYUd 0 8 9 01 dn 09 0 O GL 06 06 00 001 O 6L GOL G G 7 dn 92 dn 62 91 EE SYOLONGNOD 1V5914M12414 YVAN ASN LON OG LT J80 4 10 pleig JIM SOH SAJDNPUOD syoniy START plesg d qiq soH 9Aljonpuo2 uoN inss lq HUIYIOAA UN Jojouieliq 9PISUI RETURN PRESSURE LIST AVS Aq 41109 105 se suoneoyroeds p x 10 10041 15041 sou 1 6404 iy Bunes WSJS S oi neup u WINUI IXeuJ y jenb aunssaud Buom Ulnullulul 00161 e 1SE 16 BABY JSNW esou oi neJp u V suoneol dde vqqo Aue 101 p sn q jou pinous pue SJUSaWSJINbaJ Bunesado joo S OOL Inep H Agjueys uo p seq juo suoneoijdde 00 ol neJP Y 104 p sn aq o SI yeyo siu S0UBUIIOJSd 00 WNUWIXEUI SJNSUS o l A9 ajqedaooe uunuuiuiuJ e e1nssaid y9eq 9
11. INED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CUR RENT LEAKAGE IN ACCORDANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS 2 AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJEC TION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR THIS TOOL EXCESS FLOW OR PRESSURE MAY CAUSE A LEAK OR BURST DO NOT EXCEED RATED WORKING PRESSURE OF HYDRAULIC HOSE USED WITH THIS TOOL EXCESS PRESSURE MAY CAUSE ALEAK OR BURST CHECK TOOL HOSE COUPLERS AND CONNECTORS DAILY FOR LEAKS DO NOT FEEL FOR LEAKS WITH YOUR HANDS CONTACT WITH A LEAK MAY RESULT IN SEVERE PERSONAL INJURY IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SEE OTHER SIDE CAUTION PROTECT YOUR EYES WEAR SAFETY GOGGLES 1 Do not use damaged wheels 2 Use full throttle only while cutting 3 Use only wheels marked high speed reinforced that meet requirements of ANSI B7 5 Wheels should be no larger than 16 diameter x 5 31 thick with a 1 arbor hole and rated for 4700 rom minimum speed 4 Inspect wheel guard amp collars for damage after any wheel breakage on the machine 5 Maximum spindle speed is 4700 rpm 05868 Abrasive Cut Off Safety Label 14 inch models only except CE CAUTION
12. SONAL INJURY 03787 GPM Sticker 7 9 2000 PSI 25610 Railroad Help Desk Sticker G Stanley Hydraulic Tools Division of The Stanley Works 3810 S E Naef Road Milwaukie Oregon 97267 U S A 05152 Logo Address Decal UP models only NOTE THE INFORMATION LISTED ON THE STICKERS SHOWN MUST BE LEGIBLE AT ALL TIMES REPLACE DECALS IF THEY BECOME WORN OR DAMAGED REPLACEMENTS ARE AVAILABLE FROM YOUR LOCAL STANLEY DISTRIBUTOR The safety tag P N 15875 at right is attached to the tool when shipped from the factory Read and understand the safety instructions listed on this tag before removal We suggest you retain this tag and attach it to the tool when not in use STANLEY TOOL STICKERS amp TAGS WHEEL SIZE RPM SPINDIE o PRESS PAR PSI FLow 180 GM 51 LL 28811 Information Plaque CE models only 28409 Composite Sticker CE models only Lua 11207 Sound Power Level Sticker DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CER D TIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTA
13. TIONS EXIST REPLACE THE HOSE SAFETY DEPARTMENT INSTRUCTIONS IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROP ERLY TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG VL SIHL 4AONZH LON OG SEE OTHER SIDE SEE OTHER SIDE Shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY AFTER EACH USE STORE IN A CLEAN DRY AREA TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND ELEC TRIC LINES DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPER
14. alling abrasive wheels sound the wheel for possible damage by hanging the wheel vertically be the arbor hole and rapping lightly with a screw driver handle or similar instrument Thin organic bond wheels will produce a low drumming tone if it is physically sound If the wheel produces a dead or flat sound it may be cracked Cracked or dam aged wheels must never be used 2 Check that the surfaces of the wheel that come in contact with blotters and flanges are free of dirt and other foreign particles 3 Remove the jam nut 77 and outside collar 78 by using a box type wrench while gripping the cutting wheel 4 Install the cutting wheel Make sure blotters or labels remain on the cutting wheel 5 Reinstall the outside collar and jam nut Tighten the jam nut with a box type wrench while gripping the cutting wheel Only tighten sufficiently to prevent slippage of the wheel between the collars 78 amp 79 DRIVE SHAFT SPEED CHECK The speed of the motor output shaft should be checked at least every 100 hours of operation by trained and experienced personnel A record of the speed checks should be maintained The rated speed of the RS25 Rail Saw is 3600 rpm at 10 gpm 38 Ipm for the 16 inch 400 mm model and 4500 rpm at 10 gpm 38 Ipm for the 14 inch 350 mm model The cutting wheel must be rated for a minimum of 4700 rpm for the 16 inch 400 mm mod el and 5300 rpm for the 14 inch 350 mm model Tests should be condu
15. conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are attached to all hose purchased from Stanley Hydraulic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAY RESULT IN OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE DEATH OR SERIOUS INJURY KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC ON OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FIT CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAM TING WITH A CLEAN DRY ABSORBENT CLOTH TO REMOVE DIRT AND MOISTURE AND TEST HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE INACCORDANCE WITH AGE TO COUFLINGS IF ANY OF THESE CONDI
16. cted while operating the normal power supply used with the saw CONNECT HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect the hoses from the hydraulic power source to the hose couplers on the rail saw It is a good practice to connect the return hose first and discon nect it last to minimize or avoid trapped pressure within the rail saw motor 3 Observe flow indicators stamped on hose couplers to be sure that oil will flow in the proper direction The female coupler is the inlet coupler NOTE The pressure increase in uncoupled hoses left in the sun may result in making them difficult to connect When possible connect the free ends of operating hoses together RS25 User Manual lt 11 OPERATION OPERATING PROCEDURES CLAMPING THE RAIL SAW TO THE RAIL 1 Observe all safety precautions 2 Make sure the rail clamp assembly is tight to the disconnect pivot 60 by turning the handle 20 to tighten the disconnect pivot bolt 3 Fully extend the indicator rod located on the clamp and position the rail clamp on the rail so the clamp arms bear on the top and sides of the rail and the bell crank bears under the rail as shown in Figure 2 INDICATOR Figure 2 4 Move the rail saw along the rail until the indicator is next to the cut as shown in Figure 3 INDICATOR EDGE OF CUT LINE Figure 3 5 Tighten the bell crank to the rail by turning the clamp
17. d before use Operate the Rail Saw at no load for 30 seconds in a safe position and ensure there is no vibration or other defects detected If considerable vibration or other defects are detected stop operation of the tool immediately and determine the cause Do not use the tool until the defect is corrected If the Rail Saw is dropped with a cutting wheel in stalled the cutting wheel should be examined thor oughly before use Only use cutting wheels that comply with ANSI B7 5 ISO 525 603 Check that the maximum operating speed rpm revolutions per minute of the cutting wheel is equal to or greater than the rated shaft speed of the grind er Stanley recommends wheels rated at 4700 RPM for 16 inch models and 5300 RPM for 14 inch mod els 6 RS25 User Manual Stanley Hydraulic Tools 3810 SE Naef Rd Milwaukie Oregon 97267 U S A 26 38 Ipm 7 10 gpm 140 bar 2000 psi STANLEY STANT EY 28728 RS25 Name Tag CAUTION 7 10 GPM 26 34 LPM DO NOT EXCEED 2000 PSI 140 BAR DO NOT EXCEED SPECIFIED FLOW OR PRESSURE USE CLOSED CENTER TOOL ON CLOSED CENTER SYSTEM USE OPEN CENTER TOOL ON OPEN CENTER SYSTEM CORRECTLY CONNECT HOSES TO TOOL IN AND OUT PORTS IMPROPER HANDLING USE OR OTHER MAINTENANCE OF TOOL COULD RESULT IN A LEAK BURST OR OTHER TOOL FAILURE CONTACT AT ALEAK OR BURST CAN CAUSE OIL INJECTION INTO THE BODY FAILURE TO OBSERVE THESE PRECAUTIONS CAN RESULT IN SERIOUS PER
18. draulic Rail Saw will provide safe and dependable service if operated in accordance with the instructions given in this manual Read and under stand this manual and any stickers and tags attached to the tool and hose before operation Failure to do so could result in personal injury or equipment damage operator must start in a work area without by standers Flying debris can cause serious injury e Do not operate the tool unless thoroughly trained or under the supervision of an instructor Establish a training program for all operators to ensure safe operation e Always wear safety equipment such as goggles gloves ear and head protection and safety shoes at all times when operating the tool e The operator must be familiar with all prohibited work areas such as excessive slopes and danger ous terrain conditions e Maintain proper footing and balance at all times Do not inspect or clean the tool while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury e Always connect hoses to the tool hose couplers be fore energizing the hydraulic power source Be sure all hose connections are tight and are in good condi tion Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause higher the normal temperatures at the tool which can result in operator discomfort Do not operate a damaged improperly adjusted or incom
19. ety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This signal word indicates a potentially hazardous situation which if not avoid ed may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in dam age to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel 4 gt RS25 User Manual SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose These safety precautions are given for your safety Re view them carefully before operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional pre cautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The model RS25 Hy
20. eyhydraulic com and select the Warranty tab NOTE The warranty recording form must be submitted to validate the warranty SERVICING THE STANLEY HYDRAULIC RAIL SAW This manual contains safety operation and routine mainte nance instructions Stanley Hydraulic Tools recommends that servicing of hydraulic tools other than routine main tenance must be performed by an authorized and certified dealer Please read the following warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative STANLEY RS25 User Manual lt 3 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair ac tions which if not strictly followed could result in a life threatening situation bodily injury or damage to equipment A DANGER IMPORTANT NL ig This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situation which if not avoided will result in death or serious injury This saf
21. hese are general hydraulic system requirements See tool specification page for tool specific requirements 10 gt RS25 User Manual STANLEY OPERATION PRE OPERATION PROCEDURES CHECK HYDRAULIC POWER SOURCE 1 Using a calibrated flowmeter and pressure gauge check that the hydraulic power source develops a flow of 9 10 5 gpm 34 40 lpm at 2000 psi 140 bar 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2200 2300 psi 152 159 bar minimum 3 Check that the hydraulic circuit matches the tool for open center OC operation CHECK TOOL 1 Make sure all tool accessories are correctly in Stalled Failure to install tool accessories properly can result in damage to the tool or personal injury There should be no signs of leaks The tool should be clean with all fittings and fasten ers tight CHECK TRIGGER MECHANISM 1 Check that the trigger operates smoothly and is free to travel between the ON and OFF positions CHECK GUARD ASSEMBLY 1 Inspect the wheel guard assembly for cracks and other structural damage INSTALLING AND REMOVING ABRASIVE CUTTING WHEELS NOTE Use 14 in 350 mm diameter for 14 in model or 16 in 400 mm diameter for 16 in model abrasive cut ting wheels with a 1 in arbor hole Only use cutting wheels which comply with ANSI B7 5 ISO 525 603 Make sure the paper labels or blotters are installed between the wheel and collars 1 Before inst
22. htlinie Standards Nr Prufung durch Directives Normes Num ro Organisme agr Directriz Los Normas No Aprobado Direttiva Norme n Collaudato EN ISO 3744 2009 20643 2005 19432 2006 Machinery Directive 2006 42 EC 2006 5 Special Provisions None Spezielle Bestimmungen Dispositions particuli res Provisiones especiales Disposizioni speciali 6 Representative in the Union Patrick Vervier Stanley Dubuis 17 19 rue Jules Berthonneau BP 3406 41034 Blois Cedex France Vertreter in der Union Repr sentant dans l union Representante en la Union Rappresentante presso l Unione Done at Ort Fait Dado en Fatto a Stanley Hydraulic Tools Milwaukie Oregon USA Date Datum le Fecha Data 1 4 11 Signature Unterschrift Signature Firma Firma 4 FA Position Position Fonction Cargo Posizione Engineering Manager 1 4 2011 2 gt RS25 User Manual STANLEY TABLE OF CONTENTS DECLARATION FONN MV 2 PET PUSS 4 TETTE INN 5 190 STORES RTS ma eee ee ee ee 7 4205676 A ME DE ELE 8 H RECOMMENDATION G ES a sce fno Ded tie nu cile 9 FIGURE 1 TYPICAL HOSE CONNECTIONS 9 MERE QI ENENTS nee ee ere eee D ee ee re ee ee 10 OPERATION 9 11 F OLUUE 12 FIGURE 7 53 12 TOOL PROTE NONE 14 OBS OT AM EM DE Md 15 PER ie en 16 NESE hr 16 R929 PARTS IL RO ec a m al 17 ROZI PART ii ii 0 0 18 IMPORTANT To fill out a Product Warranty Recording form and for information on your warranty visit Stanl
23. m r FLon CONTROL 14 N MODEL ONLY oss WHEEL SAFETY LABEL 14 1N MODEL oem a owscw 0000 s 30002 poumecaw rs sos r semxem s 2000 r esr ss oes r RETANNGRNG s xen 2 wase oooO s sme r DISCONNECT PIVOT 18 RS25 User Manual PART ITEM NO QTY DESCRIPTION wr sersorew e sos am sim awe 1 nnez sun 14 N MODEL LR WHEEL GUARD 16 IN MODEL LOW SPARK SEE PHOTO PAGE 19 m Jie r sem 0000 s 2029 1 CARRIAGE BOLT foo forsee z ws 00000 s 0906 WACHINE SOREW 00 dl PURCHASED AS AN ASSEMBLY EE Laud li MOTOR ASSY 14 IN CAN ONLY BE PURCHASED i AN ASSEMBLY os ums s Lock wasneR erar 1 MALE COUPLER BODY AEROGUP AEROQUIP D 0027 1 HOSE ASSY AEROQUI P 39071 1 O RING 14 NOBEL D 004 r QUAD RING 4 MODEL s 1 COMPOSITE STICKER M IN MODEL p mme i WWMETAG MINMODED 0 RS25 PARTS LIST mar Aa Verify the correct model number before ordering ITEM NO QTY DESCRIPTION NOT SOLD INDIVIDUALLY CESTICKER HINMODE 128 28811 1 INFORMATION PLAQUE 14 IN MODEL no s sereRTonEw 129 ewm r morras o O wes r en Item 133 P N 05152 Logo Address Decal UP Model Only WHEEL GUARD 16 INCH LOW SPARK P N 73168 STANLEY RS25 User Manual lt 19 Stanley Hydraulic Tools
24. ower link toward the operator un til the detent can be re engaged in one of the holes away from the top dead center hole This positions the saw lower so that the flange of the rail may be easily cut If the detent has been removed in favor of using the capscrews as stops for the lower link simply move the lower link toward the capscrew closest to the op erator If the wheel is worn such that it will not completely cut through the rail loosen the clamp lever on the saw and rotate the saw to allow cutting from the op posite side Readjust the lower link as required and finish the cut OPERATION DETACHING THE UPPER AND LOWER LINKS The upper and lower links of the rail clamp assembly can be detached from the motor mount 50 by unscrew ing the handle 20 SAW STORAGE By disengaging the double cam 52 the rail clamp as sembly can be rotated so that the entire saw has a flatter profile for storage Do not store the saw with the abrasive wheel attached CARE OF ABRASIVE CUT OFF WHEELS All abrasive cut off wheels are breakable and therefore care must be exercised during handling and storage to prevent damage Wheels should be laid on a flat rigid surface away from excessive heat or moisture Wheels should not be stored where they will be exposed to high humidity water other liquids or freezing temperature If wheels are supplied with blotters attached suitable separators should be used to preserve fla
25. pletely assembled tool Never wear loose clothing that can get entangled in the working parts of the tool Keep all parts of your body away from the rotating parts Long hair or loose clothing can become drawn into rotating components Always use accessories that conform to the speci fications given in the OPERATION section of this manual Do not operate the tool with the wheel guard re moved Release the trigger if the power supply has been in terrupted Keep the wheel off all surfaces when starting the rail saw To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained per sonnel Always hold the tool with both hands when the unit is running Use a firm grip Make sure the wheel has stopped before setting the tool down Always carry the tool with the wheel stopped Inspect the wheel guard and collars for damage af ter any wheel breakage Do not operate the tool in the vicinity of flammable materials Never exceed the maximum operating speed marked on the wheel Do not attempt to adjust the flow control in the valve handle Eye injury and cutting or severing of body parts is possible if proper procedures are not followed RS25 User Manual lt 5 SAFETY PRECAUTIONS CUTTING WHEEL SAFETY Do not store or transport the saw with the wheel in Stalled Ensure that the cutting wheel is correctly mounted and tightene
26. screw 75 clockwise 12 RS25 User Manual 6 While holding onto the upper link of the rail clamp assembly near the red knob of the handle release the detent 129 by turning the knob and then posi tion the lower link forward away from the operator until the detent can be re engaged in one or the oth er of the two holes away from the top dead center hole This positions the saw so that the operator may stand erect while cutting the rail and also allows the saw to cut down to the flange of the rail An optional method is to disengage the detent and adjust the capscrews see Figure 2 as required 7 Adjust the wheel guard 87 so that it does not in terfere with the cutting process and cuttings are di rected away from the operator SAWING THE RAIL 1 Always start the rail saw with the cutting wheel away from the work surface 2 Start the cut with the wheel rotating NOTE Do not bump the rail Feed the wheel through the material as fast as possible without allowing the wheel to reduce its speed Cutting through the material too slowly allows heat expansion and can cause wheel pinching in the material Pinching the wheel from heat expansion is one of the most common causes of wheel breakage 3 Starting at the top of the rail cut straight down while rocking the handle back and forth Cut down until near the flange 4 When near the flange stop the saw release the de tent and move the l
27. se as viewed from the end of the motor shaft Saw cuts too slow Insufficient fluid flow or too high back Check hydraulic supply If hydraulic pressure or relief valve set too low supply is correct have unit serviced by authorized dealer Wrong wheel for material being cut Use correct wheel Fluid leakage Seal failure Do not use Have serviced by an authorized dealer Off center cut and binding Bearings worn on link arms Have unit serviced by an authorized dealer Incorrect cutting technique Review operating procedures STANLEY RS25 User Manual 15 SPECIFICATIONS Wheel Capacity 14 inch 60 EEE 14 in 35 5 cm Dia x 25 4 mm Arbor ANSI B7 5 ISO 525 603 16 inch 10061 16 in 41 cm Dia x 1 in Arbor ANSI B7 5 ISO 525 603 FESTER RARE TU 1800 2000 psi 124 140 bar Maximum Back PIeSSUIG sa 250 psi 17 bar FOR bed HTMA Class RR 9 10 5 gpm 34 40 lpm ET L PN P 30 lpm 138 bar abu Ece m s n 40 Ipm 138 bar POHiit c 06 8 SAE O ring COUDE ii b s n HTMA EHTMA Flush Face Type OS 10 o HE Yes Weight with hose whips amp CoupleTs 0 cece 14 1 1b 6 40 kg eie L baa r 36 inches 92 cm EU 11 inches 28
28. tness COLD WEATHER OPERATION If the saw is to be used during cold weather preheat the hydraulic fluid at low engine speed When using the normally recommended fluids fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes be fore use INVESTIGATION OF WHEEL BREAKAGE lf a wheel breaks during use a careful investigation should be conducted by to determine the cause of the breakage The cause must then be corrected before us ing the saw again If unable to determine the cause of breakage the wheel manufacturer should be consulted RS25 User Manual 4 13 TOOL PROTECTION amp CARE NOTICE In addition to the Safety Precautions found in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before con nection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydrau lic tools Failure to do so may result in damage to the quick couplers and cause overheating of the hy draulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse cir cuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts recommended by
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